Method for forming single crystal components using additive manufacturing and re-melt

ABSTRACT

A method is provided for manufacturing a component. This method includes additively manufacturing a crucible for casting of the component. A metal material is directionally solidified within the crucible to form a metal single crystal material. A sacrificial core is removed to reveal a metal single crystal component with internal passageways. A component is provided for a gas turbine engine that includes a metal single crystal material component with internal passageways. The metal single crystal material component was additively manufactured of a metal material concurrently with a core that forms the internal passageways. The metal material was also remelted and directionally solidified.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 61/929,739 filed Jan. 21, 2014, which is hereby incorporated hereinby reference in its entirety.

BACKGROUND

The present disclosure relates to components for a gas turbine engineand, more particularly, to the additive manufacture thereof.

Gas turbine engines typically include a compressor section to pressurizeairflow, a combustor section to burn a hydrocarbon fuel in the presenceof the pressurized air, and a turbine section to extract energy from theresultant combustion gases.

In the gas turbine industry, methods to directly fabricate componentswith internal passageways, such as blades and vanes within the turbinesection, using additive manufacturing invite much attention. Since acomponent is produced in a continuous process in an additivemanufacturing operation, features associated with conventionalmanufacturing processes such as machining, forging, welding, casting,etc. can be eliminated leading to savings in cost, material, and time.

An inherent feature of components fabricated by additive manufacturingis that the microstructures are polycrystalline. However, numerous typesof turbine components require a single crystal microstructure towithstand the high temperature, high stress operating environment in ahot gas stream.

SUMMARY

A method of manufacturing a component, according to one disclosednon-limiting embodiment of the present disclosure, includes additivelymanufacturing a crucible for casting of the component. A metal materialwithin the crucible is directionally solidified to form a metal singlecrystal material. A sacrificial core is removed to reveal a metal singlecrystal component with internal passageways.

In a further embodiment of the present disclosure, the metal material isselected from the group consisting of a nickel based superalloy, cobaltbased superalloy, iron based superalloy, and mixtures thereof.

In a further embodiment of the present disclosure, the crucible isadditively manufactured of a material selected from the group consistingof a ceramic material, a refractory metal alloy and hybrids thereof.

In a further embodiment of the present disclosure, the metal material isa powder.

In a further embodiment of the present disclosure, the crucible includesa core at least partially within a shell. The core at least partiallydefines the internal passageways within the component.

In a further embodiment of the present disclosure, the method includesforming the core via additive manufacturing.

In a further embodiment of the present disclosure, the method includesforming the shell via additive manufacturing.

In a further embodiment of the present disclosure, the core at leastpartially defines the internal passageways within the component.

A method of manufacturing a component, according to another disclosednon-limiting embodiment of the present disclosure, includes additivelymanufacturing the component of a metal material. A core is additivelymanufactured at least partially within the component. The additivelymanufactured component and the additively manufactured core are at leastpartially encased within a shell. The additively manufactured componentis melted. The metal material of the additively manufactured componentis directionally solidified to form a metal single crystal materialcomponent. The shell and the additively manufactured core are removed toreveal a metal single crystal component with internal passageways.

In a further embodiment of the present disclosure, the metal material isa powder.

In a further embodiment of the present disclosure, the core at leastpartially defines the internal passageways within the component.

In a further embodiment of the present disclosure, the method includesconcurrently additively manufacturing the component of a metal materialand the core within the component.

In a further embodiment of the present disclosure, the core at leastpartially defines microchannels within the component.

In a further embodiment of the present disclosure, the microchannels areadditively manufactured of a refractory material and the internalpassageways are manufactured of a ceramic material.

In a further embodiment of the present disclosure, the additivemanufacturing is performed by a multi-powder bed system.

In a further embodiment of the present disclosure, the method includesapplying a wax material at least partially onto the component.

In a further embodiment of the present disclosure, the method includesmelting the wax material prior to melting the additively manufacturedcomponent.

In a further embodiment of the present disclosure, the method includesapplying the wax material to an airfoil portion of the component.

A component for a gas turbine engine, according to another disclosednon-limiting embodiment of the present disclosure, includes a metalsingle crystal material component with internal passageways, where themetal single crystal material component has been additively manufacturedof a metal material concurrently with a core that forms the internalpassageways, and where the metal material has been remelted anddirectionally solidified.

In a further embodiment of the present disclosure, the metal singlecrystal material component includes an airfoil.

In a further embodiment of the present disclosure, the metal singlecrystal material component is a rotor blade.

The foregoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated otherwise.These features and elements as well as the operation thereof will becomemore apparent in light of the following description and the accompanyingdrawings. It should be understood, however, the following descriptionand drawings are intended to be exemplary in nature and non-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features will become apparent to those skilled in the art fromthe following detailed description of the disclosed non-limitingembodiment. The drawings that accompany the detailed description can bebriefly described as follows:

FIG. 1 is a schematic cross-section of an example gas turbine enginearchitecture;

FIG. 2 is a schematic cross-section of another example gas turbineengine architecture;

FIG. 3 is an enlarged schematic cross-section of an engine turbinesection;

FIG. 4 is a perspective view of a turbine blade as an example componentwith internal passages;

FIG. 5 is a schematic cross-section view of the showing the internalpassages;

FIG. 6 is a perspective view of a crucible for casting the turbineblade;

FIG. 7 is a schematic lateral cross-section view of the examplecomponent with internal passages within the crucible;

FIG. 8 is a flow chart of one disclosed non-limiting embodiment of amethod for fabricating an example component with internal passages;

FIG. 9 is a flow chart of another disclosed non-limiting embodiment of amethod for fabricating an example component with internal passages;

FIG. 10 is a lateral cross-section view of an example component withinternal passages within a crucible as manufactured by the method ofFIG. 9;

FIG. 11 is a flow chart of another disclosed non-limiting embodiment ofa method for fabricating an example component with internal passages;

FIG. 12 is a lateral cross-section view of an example component withinternal passages within a crucible as manufactured by the method ofFIG. 11;

FIG. 13 is a flow chart of another disclosed non-limiting embodiment ofa method for fabricating an example component with internal passages;

FIG. 14 is a lateral cross-section view of an example component withinternal passages within a crucible as manufactured by the method ofFIG. 13;

FIG. 15 is a flow chart of another disclosed non-limiting embodiment ofa method for fabricating an example component with internal passages;and

FIG. 16 is a lateral cross-section view of an example component withinternal passages within a crucible and coated with a wax layer asmanufactured by the method of FIG. 15.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates a gas turbine engine 20. The gasturbine engine 20 is disclosed herein as a two-spool turbo fan thatgenerally incorporates a fan section 22, a compressor section 24, acombustor section 26 and a turbine section 28. Alternative enginearchitectures 200 might include an augmentor section 12, an exhaust ductsection 14 and a nozzle section 16 (see FIG. 2) among other systems orfeatures. The fan section 22 drives air along a bypass flowpath whilethe compressor section 24 drives air along a core flowpath forcompression and communication into the combustor section 26 thenexpansion through the turbine section 28. Although depicted as aturbofan in the disclosed non-limiting embodiment, it should beunderstood that the concepts described herein are not limited to usewith turbofans as the teachings may be applied to other types of turbineengine architectures such as turbojets, turboshafts, and three-spool(plus fan) turbofans.

The engine 20 generally includes a low spool 30 and a high spool 32mounted for rotation about an engine central longitudinal axis Arelative to an engine static structure 36 via several bearing structures38. The low spool 30 generally includes an inner shaft 40 thatinterconnects a fan 42, a low pressure compressor (“LPC”) 44 and a lowpressure turbine (“LPT”) 46. The inner shaft 40 may drive the fan 42directly or through a geared architecture 48 to drive the fan 42 at alower speed than the low spool 30. An exemplary reduction transmissionis an epicyclic transmission, namely a planetary or star gear system.

The high spool 32 includes an outer shaft 50 that interconnects a highpressure compressor (“HPC”) 52 and a high pressure turbine (“HPT”) 54. Acombustor 56 is arranged between the high pressure compressor 52 and thehigh pressure turbine 54. The inner shaft 40 and the outer shaft 50 areconcentric and rotate about the engine central longitudinal axis A whichis collinear with their longitudinal axes.

Core airflow is compressed by the LPC 44 then the HPC 52, mixed with thefuel and burned in the combustor 56, then expanded over the HPT 54 andthe LPT 46. The turbines 46, 54 rotationally drive the respective lowspool 30 and high spool 32 in response to the expansion. The main engineshafts 40, 50 are supported at a plurality of points by the bearingstructures 38 within the static structure 36. It should be understoodthat various bearing structures 38 at various locations mayalternatively or additionally be provided.

With reference to FIG. 3, an enlarged schematic view of a portion of theturbine section 28 is shown by way of example; however, other enginesections will also benefit herefrom. A full ring shroud assembly 60within the engine case structure 36 supports a blade outer air seal(BOAS) assembly 62 with a multiple of BOAS segments 64 proximate to arotor assembly 66 (one schematically shown).

The full ring shroud assembly 60 and the blade outer air seal (BOAS)assembly 62 are axially disposed between a forward stationary vane ring68 and an aft stationary vane ring 70. Each vane ring 68, 70 includes anarray of vanes 72, 74 that extend between a respective inner vanesupport 76, 78 and an outer vane support 80, 82. The outer vane supports80, 82 are attached to the engine case structure 36.

The rotor assembly 66 includes an array of blades 84 circumferentiallydisposed around a disk 86. Each blade 84 includes a root 88, a platform90 and an airfoil 92 (also shown in FIG. 4). The blade roots 88 arereceived within a rim 94 of the disk 86 and the airfoils 92 extendradially outward such that a tip 96 of each airfoil 92 is closest to theblade outer air seal (BOAS) assembly 62. Each BOAS segment 64 may bemanufactured of an abradable material to accommodate potentialinteraction with the rotating blade tips 96.

To resist the high temperature stress environment in the hot gas path ofa turbine engine, each blade 84 may be formed by casting as a singlecrystal material. It should be appreciated that although a blade 84 withinternal passageways 98 (see FIG. 5) will be described and illustratedin detail, other components including, but not limited to, vanes, fuelnozzles, airflow swirlers, combustor liners, turbine shrouds, vaneendwalls, airfoil edges and other gas turbine engine components W mayalso be manufactured in accordance with the teachings herein.

While not to be limited to any single method, an additive manufacturingprocess may be utilized to form a crucible 100 (see FIG. 6) to cast theblade 84 and internal passageways 98 therein. Example additivemanufacturing processes include, but are not limited to,Sterolithography (SLS), Direct Selective Laser Sintering (DSLS),Electron Beam Sintering (EBS), Electron Beam Melting (EBM), LaserEngineered Net Shaping (LENS), Laser Net Shape Manufacturing (LNSM),Direct Metal Deposition (DMD), Direct Metal Laser Sintering (DMLS) andothers. The additive manufacturing process facilitates manufacture ofrelatively complex components, minimize assembly details and minimizemulti-component construction. The additive manufacturing processessentially “grows” articles from three-dimensional information, forexample, a three-dimensional computer aided design (CAD) model. Thethree-dimensional information is converted into a plurality of slices,each slice defining a cross section of the article for a predeterminedheight of the slice. The additive manufactured component is then “grown”slice by slice, or layer by layer.

With reference to FIG. 6, the additive manufactured crucible 100generally includes a core 102 and a shell 104. The shell 104 generallydefines the outer surface of the component W while the core 102 formsthe internal surfaces such as the internal passages. That is, during thecasting process, the core 102 fills a volume that, when removed from thefinished casting, defines the internal passageways 98 utilized forcooling airflow. The shell 104 and the core 102 provide a mold to castcomplex exterior and interior geometries and may be formed of refractorymetals, ceramic, or hybrids thereof. The crucible 100 thereby operatesas a melting unit and/or a die.

With reference to FIG. 8, while not to be limited to any single methodof additive manufacture, a method 200 according to one disclosednon-limiting embodiment for forming single crystal superalloy componentwith internal passageways is often termed a crucible, lost wax or shellmold casting process.

In method 200, the crucible 100 is additively manufactured (Step 202).It should be appreciated that the core 102 and/or shell 104 of thecrucible 100 may be additively manufactured from feedstock materialsthat include but are not limited to ceramic material such as silica,alumina, zircon, cobalt, mullite, kaolin, refractory metals, hybrids aswell as others.

Following additive manufacture, the crucible 100 may be dried and fired(e.g., bisqued) at an intermediate temperature before high firing tofully sinter and densification. The additively manufactured crucible 100thereby forms a cavity for casting of the component W. That is, thecrucible 100 is integrally formed by the additive manufacturing processsuch that the conventional separate manufacture of the core and shellare essentially combined into a single step. It should be appreciatedthat single or multiple molds and cavities may be additivelymanufactured and assembled.

Next, the crucible may be filled with a desired metal (Step 204). Thedesired metal may include but not be limited to a superalloy or othermaterial such as nickel based superalloy, cobalt based superalloy, ironbased superalloy, and mixtures thereof in the form of a metal powderthat is melted; a molten superalloy that is then solidified; or othermaterial. In another non-limiting embodiment, the crucible may be filledwith a molten superalloy directly.

Alternatively, or in addition, a single crystal starter seed or grainselector may be utilized to enable a single crystal to form whensolidifying the component (Step 206). The solidification may utilize achill block in a directional solidification furnace. The directionalsolidification furnace has a hot zone that may be induction heated and acold zone separated by an isolation valve. The chill block andadditively manufactured crucible 100 may be elevated into the hot zoneand filled with molten super alloy. After the pour, or being molten, thechill plate may descend into the cold chamber causing a solid/liquidinterface to advance from the partially molten starter seed in the formof a single crystallographic oriented component whose orientation isdictated by the orientation of the starter seed. Casting is performedunder an inert atmosphere or vacuum to preserve the purity of thecasting.

Following solidification, the additively manufactured crucible 100 maybe removed from the solidified component W such as by caustic leaching,to leave the finished single crystal component (Step 208). Afterremoval, the component W may be further finished such as by machining,threading, surface treating, coating or any other desirable finishingoperation (Step 210).

With reference to FIG. 9, a method 300 according to another disclosednon-limiting embodiment is initiated by first additively manufacturingthe component W; e.g., a turbine blade, vane or other component withinternal cooling passages (Step 302). Again, various blades, vanes, fuelnozzles, airflow swirlers and other gas turbine engine components mayalso be manufactured in accordance with the teachings herein.

In this disclosed non-limiting embodiment, the additively manufacturedcomponent W is manufactured with a multi-feedstock additivemanufacturing process such as a two-powder bed system. A structure 130of the component W is manufactured of the desired superalloy while thecore 102 and shell 104 of the crucible 100 are manufactured of adifferent material such as a ceramic, a refractory metal, or othermaterial which is later removed (see FIG. 10). That is, the location forthe internal cooling passages of the component W are additivelymanufactured of the ceramic, refractory metal, or other material core102 that is later removed and the shell 104 that surrounds the structure130 is also additively manufactured of the ceramic, refractory metal, orother material that is later removed.

The structure 130 of the component W, being additively manufactured, maybe a polycrystalline superalloy that may not be acceptable as acomponent in the gas turbine engine such as within the turbine section.That is, the structure 130 may require a single crystal microstructureto withstand the high temperature, high stress operating environment ofthe gas turbine engine that is not typically achieved by direct additivemanufacture.

To thereby facilitate formation of the single crystal microstructure theadditively manufactured superalloy structure 130 is re-melted within thecrucible 100 (Step 304). That is, the additively manufactured superalloystructure 130 is re-melted and directionally solidifying to form a metalsingle crystal structure within the additively manufactured crucible 100that were concurrently additively manufactured in step 302. As describedabove, the solidification of the superalloy structure 130 may utilize achill block in a directional solidification furnace. It should beappreciated that various solidification processes that may include thechill plate, withdrawal rate, and pigtail or starter seed to directionalsolidify the molten material into single crystal if so desired.

Following solidification, the additively manufactured crucible 100 maybe removed from the solidified component W such as by caustic leaching,to leave the finished single crystal component (Step 306). Afterremoval, the component W may be further finished such as by machining,threading, surface treating, coating or any other desirable finishingoperation (Step 308).

With reference to FIG. 11, a method 400 according to another disclosednon-limiting embodiment is initiated with the additively manufacturedcomponent W manufactured with a multi-feedstock additive manufacturingprocess such as three-powder bed system (Step 402).

A structure 140 of the component W is manufactured of the desiredsuperalloy while the core 102 and shell 104 of the crucible 100 aremanufactured of a different material (see FIG. 12). Locations for theinternal cooling passages 142 of the component W are additivelymanufactured of ceramic material and locations for microcircuits 144 ofthe component W are additively manufactured of a refractory metalmaterial. The microcircuit 144 is relatively smaller than, and may belocated outboard of, the internal cooling passages 142 to facilitatetailorable, high convective efficiency cooling. The microcircuits may beformed of refractory metals to include not be limited to molybdenum (Mo)and Tungsten (W) that possess relatively high ductility for formationinto complex shapes and have melting points that are in excess oftypical casting temperatures of nickel based superalloys but can beremoved, such as through chemical removal, thermal leeching, oroxidation methods, leaving behind a cavity forming the microcircuit 144.

As described above, to facilitate formation of the single crystalmicrostructure, the additively manufactured superalloy is re-meltedwithin the crucible 100 (Step 404) formed in the step 402. As alsodescribed above, it should be appreciated that various solidificationprocesses that may include the chill plate, withdrawal rate, and pigtailor starter seed to directional solidify the molten material into singlecrystal if so desired.

Following solidification, the additively manufactured crucible 100 maybe removed from the solidified component W such as by caustic leaching,to leave the finished single crystal structure 140 of the component W(Step 406). After removal, the component W may be further finished suchas by machining, threading, surface treating, coating or any otherdesirable finishing operation (Step 408).

With reference to FIG. 13, a method 500 according to another disclosednon-limiting embodiment is initiated with the additively manufacturedcomponent W manufactured with a multi-feedstock additive manufacturingprocess such as two-powder bed system (Step 502). A structure 150 of thecomponent W is manufactured of the desired superalloy whilemicrocircuits 152 of the component W are additively manufactured of arefractory metal material. That is, the refractory metal material isadditively manufactured within the structure 150 where the microcircuitswill be.

In this disclosed non-limiting embodiment, the internal cooling passages154 of the component W may be filled with a ceramic slurry to form thecore 102 (Step 504). The slurry may include, but is not be limited to,ceramics commonly used as core materials including, but not limited to,silica, alumina, zircon, cobalt, mullite, and kaolin. In the next step,the ceramic core may be cured in situ by a suitable thermal process ifnecessary (Step 506).

Next, a ceramic shell may then be formed over the structure 150 andinternal ceramic core (Step 508). The ceramic shell may be formed overthe structure 150 and the ceramic core by dipping into a slurry of shellmold ceramic powder and binder to form a layer of ceramic. The layer isdried and the process repeated for as many times as necessary to form agreen (e.g., unfired) ceramic shell mold. The thickness of the greenceramic shell mold at this step may be from about 0.2-1.3 inches (5-32mm). The green shell mold may then be bisque fired at an intermediatetemperature to partially sinter the ceramic and burn off the bindermaterial. The mold may then be high fired at a temperature between about1200° F. (649° C.) to about 1800° F. (982° C.) from about 10 to about120 minutes to sinter the ceramic to full density to foal′ the shellmold.

As described above, to facilitate formation of the single crystalmicrostructure, the additively manufactured superalloy is re-meltedwithin the crucible 100 (Step 510). As also described above, thesolidification of the superalloy structure 150 may utilize a chill blockin a directional solidification furnace. It should be appreciated thatvarious solidification processes that may include the chill plate,withdrawal rate, and pigtail or starter seed to directional solidify themolten material into single crystal if so desired.

Following solidification, the additively manufactured crucible 100 maybe removed from the solidified component W such as by caustic leaching,to leave the finished single crystal structure 150 of the component W(Step 512). After removal, the component W may be further finished suchas by machining, threading, surface treating, coating or any otherdesirable finishing operation (Step 514).

With reference to FIG. 15, a method 600 according to another disclosednon-limiting embodiment facilitates a high quality surface finish. Asdescribed above, the additively manufactured structure of the componentW is formed of a desired superalloy that itself forms the cavity patternfor the crucible. The additively manufactured structure of the componentW is then re-melted within the crucible to facilitate formation of thesingle crystal microstructure. However, the crucible, being formed bythe additive manufactured structure, may have a relatively poor surfacefinish typically not acceptable for use as a blade or vane in the gasturbine engine. That is, the airfoil surfaces of the blade and vanes inthe gas turbine engine necessarily require particular contour tolerancesand surface finishes that are typically not achieved by direct additivemanufacture or may not be achieved in an additive manufacturing processwithin a reasonable cycle time.

To further improve the surface finish, the structure 160 of thecomponent W is additively manufactured of the desired superalloy (Step602) as described above with desired internal cooling passages 162and/or microcircuits 164 filled with a core ceramic slurry or beadditively manufactured. That is, any of the above-described embodimentsthat additively manufacture the structure and/or the core of thecrucible may initially be utilized.

Next, a relatively thin layer of a wax material 166 is applied to anexternal, aerodynamic surface 168 of the structure 160 such as theairfoil section of a turbine blade (Step 604; FIG. 16). The wax materialessentially smoothens the relatively rough surface of the as additivelymanufactured structure 160.

Next, a ceramic shell 104 is faulted over the additively manufacturedstructure 160 (Step 606). The ceramic shell may be formed over theadditively manufactured structure 160 by dipping or other process.

The relatively thin layer of a wax material 166 is then removed (Step608). The relatively thin layer of a wax material 166 may be removed byheating or other operation that but does not otherwise effect theadditively manufactured structure 160.

Then, as described above, to facilitate formation of the single crystalmicrostructure the additively manufactured superalloy structure 160 isre-melted within the shell of the crucible (Step 610). As also describedabove, it should be appreciated that various solidification processesthat may include the chill plate, withdrawal rate, and pigtail orstarter seed to directional solidify the molten material into singlecrystal if so desired. It should be further appreciated that there-melting (Step 610) may alternatively be combined with the removal ofthe relatively thin layer of a wax material 166 (Step 608).

Following solidification, the solidified component W may be removed fromthe crucible by caustic leaching, to leave the finished single crystalstructure 160 of the component W (Step 612). After removal, thecomponent W may be further finished such as by machining, threading,surface treating, coating or any other desirable finishing operation(Step 614).

The method disclosed herein facilitates the relatively rapid additivemanufacture of single crystal microstructure components with complexinternal passages and heretofore unavailable surface finishes towithstand the high temperature, high stress operating environment of agas turbine engine environment.

It should be understood that relative positional terms such as“forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like arewith reference to the normal operational attitude of the vehicle andshould not be considered otherwise limiting.

It should be understood that like reference numerals identifycorresponding or similar elements throughout the several drawings. Itshould also be understood that although a particular componentarrangement is disclosed in the illustrated embodiment, otherarrangements will benefit herefrom.

Although particular step sequences are shown, described, and claimed, itshould be understood that steps may be performed in any order, separatedor combined unless otherwise indicated and will still benefit from thepresent disclosure.

The foregoing description is exemplary rather than defined by thefeatures within. Various non-limiting embodiments are disclosed herein,however, one of ordinary skill in the art would recognize that variousmodifications and variations in light of the above teachings will fallwithin the scope of the appended claims. It is therefore to beunderstood that within the scope of the appended claims, the disclosuremay be practiced other than as specifically described. For that reasonthe appended claims should be studied to determine true scope andcontent.

What is claimed is:
 1. A method of manufacturing a component,comprising: additively manufacturing a crucible for casting of thecomponent; directionally solidifying a metal material within thecrucible to form a metal single crystal material; and removing asacrificial core to reveal a metal single crystal component withinternal passageways.
 2. The method as recited in claim 1, wherein themetal material is selected from the group consisting of a nickel basedsuperalloy, cobalt based superalloy, iron based superalloy, and mixturesthereof.
 3. The method as recited in claim 1, wherein the crucible isadditively manufactured of a material selected from the group consistingof a ceramic material, a refractory metal alloy and hybrids thereof. 4.The method as recited in claim 1, wherein the metal material is apowder.
 5. The method as recited in claim 1, wherein the crucibleincludes a core at least partially within a shell, and the core at leastpartially defines the internal passageways within the component.
 6. Themethod as recited in claim 5, further comprising forming the core viaadditive manufacturing.
 7. The method as recited in claim 5, furthercomprising forming the shell via additive manufacturing.
 8. The methodas recited in claim 5, wherein the core at least partially defines theinternal passageways within the component.
 9. A method of manufacturinga component, comprising: additively manufacturing the component of ametal material; additively manufacturing a core at least partiallywithin the component; at least partially encasing the additivelymanufactured component and additively manufactured core within a shell;melting the additively manufactured component; directionally solidifyingthe metal material of the additively manufactured component to form ametal single crystal material component; and removing the shell and theadditively manufactured core to reveal a metal single crystal componentwith internal passageways.
 10. The method as recited in claim 9, whereinthe metal material is a powder.
 11. The method as recited in claim 9,wherein the core at least partially defines the internal passagewayswithin the component.
 12. The method as recited in claim 11, furthercomprising concurrently additively manufacturing the component of ametal material and the core within the component.
 13. The method asrecited in claim 11, wherein the core at least partially definesmicrochannels within the component.
 14. The method as recited in claim13, wherein the microchannels are additively manufactured of arefractory material and the internal passageways are manufactured of aceramic material.
 15. The method as recited in claim 14, wherein theadditive manufacturing is performed by a multi-powder bed system. 16.The method as recited in claim 9, further comprising applying a waxmaterial at least partially onto the component.
 17. The method asrecited in claim 16, further comprising melting the wax material priorto melting the additively manufactured component.
 18. The method asrecited in claim 16, further comprising applying the wax material to anairfoil portion of the component.
 19. A component for a gas turbineengine, comprising: a metal single crystal material component withinternal passageways; the metal single crystal material component havingbeen additively manufactured of a metal material concurrently with acore that forms the internal passageways, and the metal material havingbeen remelted and directionally solidified.
 20. The component of claim19, wherein the metal single crystal material component includes anairfoil.
 21. The component of claim 20, wherein the metal single crystalmaterial component is a rotor blade.